JP2016111273A - Solar cell module body and manufacturing method for the same, and solar cell module and manufacturing method for the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for a solar cell module body with a snow melting function capable of reducing weight of the solar cell module and suppressing contact between a solar cell and a heating element.SOLUTION: A manufacturing method for a solar cell module body includes a step of arranging a light receiving face plate 11, a solar cell 12, an electric insulation sheet 13, a heating element 14, and a back face plate 15 in this order from a light receiving face side to a back face side, and heating them at adhesive temperature to bond them by using the adhesive agent, where heatproof temperature of the electric insulation sheet 13 is higher than the adhesive temperature.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a solar cell module main body and a manufacturing method thereof, and a solar cell module and a manufacturing method thereof.

  The solar cell module includes a solar cell module main body and a heating element that heats the solar cell module main body from the back side (see, for example, Patent Document 1). The heating element melts snow on the light receiving surface of the solar cell module body by heating the solar cell module body from the back side.

JP 2014-040768 A

  Conventionally, a heating element is retrofitted to the solar cell module body, and the weight of the solar cell module has been heavy. In addition, the heating element is bulky, a space for attaching the heating element is necessary, and the work at the time of installing the module is complicated.

  Therefore, it is conceivable to incorporate a heating element into the solar cell module body in order to reduce the weight of the solar cell module and improve the efficiency of the module installation work. In this case, the solar battery cell and the heating element come into contact with each other and can be conducted.

  The present invention has been made in view of the above problems, and provides a method for manufacturing a solar cell module body with a snow melting function, which can reduce the weight of the solar cell module and suppress contact between the solar cell and the heating element. Is the main purpose.

In order to solve the above problems, according to one aspect of the present invention,
The light-receiving face plate, solar cells, electrical insulating sheet, heating element, and back plate are arranged in this order from the light-receiving face side to the back face, heated to the bonding temperature, and bonded using an adhesive. Having a process,
There is provided a method for manufacturing a solar cell module body, wherein the heat-resistant temperature of the electrical insulating sheet is higher than the adhesion temperature.

  According to one embodiment of the present invention, there is provided a method for manufacturing a solar cell module body with a snow melting function, which can reduce the weight of the solar cell module and can suppress contact between the solar cell and the heating element.

It is a flowchart which shows the manufacturing method of the solar cell module main body by one Embodiment of this invention. It is sectional drawing which decomposes | disassembles and shows the assembly obtained by assembly process S11 of FIG. It is sectional drawing which shows the solar cell module main body obtained by adhesion process S12 of FIG. It is sectional drawing which shows the solar cell module by one Embodiment of this invention.

  Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. In the drawings, the same or corresponding components are denoted by the same or corresponding reference numerals, and description thereof is omitted. In this specification, “to” representing a numerical range means a range including numerical values before and after the numerical range.

  FIG. 1 is a flowchart showing a method for manufacturing a solar cell module body according to an embodiment of the present invention. FIG. 2 is an exploded cross-sectional view of the assembly obtained in the assembly step S11 of FIG. FIG. 3 is a cross-sectional view showing the solar cell module body obtained by the bonding step S12 of FIG.

  As shown in FIG. 1, the manufacturing method of a solar cell module body includes an assembly step S11 and an adhesion step S12.

  In the assembly step S11, as shown in FIG. 2, the light receiving face plate 11, the solar battery cell 12, the electrical insulating sheet 13, the heating element 14, and the back face plate 15 are directed from the light receiving face 10a side to the back face 10b side. The assembly 16 is manufactured by arranging in this order.

  The assembly 16 includes, for example, the light receiving face plate 11, the first adhesive sheet 21, the solar battery cell 12, the second adhesive sheet 22, the electrical insulating sheet 13, the third adhesive sheet 23, the heating element 14, The fourth adhesive sheet 24 and the back plate 15 are provided in this order from the light receiving surface 10a side to the back surface 10b side.

  In the bonding step S12, the assembly 16 is heated to the bonding temperature, and the components of the assembly 16 (the light receiving surface plate 11, the solar battery cell 12, the electrical insulating sheet 13, the heating element 14, and the back plate 15) are bonded with an adhesive. . In the bonding step S12, the assembly 16 may be pressed in the stacking direction using a laminating machine or a press. Adhesion process S12 is performed under pressure conditions over the temperature of 150-170 degreeC, and the time for 15-40 minutes.

  The adhesive has translucency so that light transmitted through the light receiving face plate 11 is taken into the solar battery cell 12. The adhesive is a thermoplastic resin such as EVA (Ethylene Vinyl Acetate: ethylene-vinyl acetate copolymer), PVA (polyvinyl acetal resin), EEA (ethylene-acrylic acid ester copolymer), olefin resin, and in some cases. Although it is formed of a thermosetting resin, EVA is preferably used because it is easily available. The melting point of EVA used for bonding solar cell modules is about 70 to 100 ° C.

  As the adhesive, the first adhesive sheet 21, the second adhesive sheet 22, the third adhesive sheet 23, and the fourth adhesive sheet 24 are used. These adhesive sheets may be formed of different materials, but may be formed of the same material. In the latter case, it is easy to determine the bonding conditions. In the latter case, the adhesive layer 17 is obtained by integrating these adhesive sheets.

  The solar cell module main body 10 shown in FIG. 3 is obtained by the bonding step S12.

  The solar cell module body 10 includes a light receiving surface plate 11, solar cells 12, an electrical insulating sheet 13, a heating element 14, and a back plate 15 in this order from the light receiving surface 10a side to the back surface 10b side. . The light-receiving face plate 11 and the back face plate 15 are bonded by an adhesive layer 17, and the solar battery cell 12, the electrical insulating sheet 13, and the heating element 14 are sealed inside the adhesive layer 17. The electrical insulating sheet 13 may be the same size as the light receiving surface plate 11 and the back plate 15, and the side surface of the electrical insulating sheet 13 may be exposed.

  The light receiving surface plate 11 is a plate disposed on the light receiving surface 10a side with respect to the solar battery cell 12 as a reference. The light receiving face plate 11 has translucency with respect to sunlight. The light transmitted through the light receiving face plate 11 is taken into the solar battery cell 12. An antireflection film may be formed on the light receiving surface of the light receiving surface plate 11. Light reflection at the light-receiving face plate 11 can be reduced, and sunlight capture efficiency can be improved.

  The light-receiving face plate 11 may be, for example, a glass plate or a resin plate, but is preferably a glass plate from the viewpoint of waterproofness, fireproofing, durability, and the like. The glass plate as the light-receiving face plate 11 may be either untempered glass or tempered glass.

  The solar battery cell 12 is disposed between the light receiving face plate 11 and the back face plate 15 and converts light energy into electric energy. The solar battery cell 12 may be any of silicon-based, compound-based, and organic-based. A plurality of solar cells 12 may be provided in one solar cell module body 10, and the plurality of solar cells 12 are connected in series or in parallel.

  The back plate 15 is a plate arranged on the back surface 10b side with the solar battery cell 12 as a reference. The back plate 15 is waterproof. The back plate 15 may or may not have translucency. The back plate 15 may be either a glass plate or a resin plate, for example, but is preferably a resin plate or a thin glass having a thickness of 2 mm or less from the viewpoint of lightness and the like. The back plate 15 is preferably a resin plate from the viewpoint of workability of the wiring hole.

  The heating element 14 generates heat when energized and melts snow on the light receiving surface 10a. The heating element 14 is not used in summer when snow does not fall. This is because the lower the temperature of the solar battery cell 12, the higher the power generation efficiency of the solar battery cell 12.

  The heating element 14 is operated based on, for example, a detection result of a snowfall sensor. The snowfall sensor detects a snowfall condition (including a snow cover condition) near the solar cell module. As a snowfall sensor, a general sensor can be used. For example, the snowfall sensor includes a sensor that detects pressure due to the weight of snow, a sensor that detects infrared rays reflected by snow, and a sensor that detects moisture by melting snow. When detecting moisture, rain and snow are discriminated based on the outside air temperature.

  The heating element 14 is controlled so that, for example, the temperature of the heating element 14 becomes a set temperature during operation. The control may be either feedback control or feedforward control.

  The heating element 14 may be a planar heating element. A planar heating element is preferable because a mechanism for uniforming heat (such as a soaking plate) is unnecessary. The planar heating element has a heating part formed of a knitted fabric containing conductive fibers and an electrode part for energizing the heating part. Since the planar heating element has a knitted fabric structure and is flexible, the risk that the heating part is disconnected and does not generate heat when the solar cell module body is repeatedly deformed by wind or the like can be greatly reduced. Even if a part of the conductive fiber is disconnected, the heat generation function is not impaired.

  The conductive fiber includes an organic fiber and a carbon nanotube that covers the surface of the organic fiber. Carbon nanotubes form a conductive layer. The proportion of the carbon nanotubes is preferably 0.1 to 50 parts by mass with respect to 100 parts by mass of the organic fiber from the viewpoints of adhesion to the organic fiber and conductive heat generation.

  The organic fiber may be composed of at least one selected from the group consisting of a polyester resin, a polyamide resin, a polyolefin resin, and an acrylic resin. Adhesion and resistance to bending fatigue of carbon nanotubes are good.

  The conductive fiber preferably contains a multifilament yarn or spun yarn having a single yarn fineness of 11 dtex or less from the viewpoint of flexibility and flexibility.

  When the conductive fiber includes a composite yarn such as a multifilament yarn or a spun yarn, it is preferable that the conductive layer (carbon nanotube) is attached with a covering ratio that covers 60% or more of the surface of the composite yarn.

  In order for the conductive fibers to adhere the carbon nanotubes inside the composite yarn, the organic fibers may be immersed in a dispersion containing the carbon nanotubes while vibrating the organic fibers.

The line electrical resistance value at 20 ° C. of the conductive fiber may be about 1 × 10 ⁻¹ to 1 × 10 ⁵ Ω / cm from the viewpoint of conductive heat generation.

  The conductive fiber may form an insulating layer on the carbon nanotube (or conductive layer) except for the contact portion with the electrode portion from the viewpoint of suppressing contact current between the conductive fibers.

  The knitted fabric may be a woven fabric composed of warps composed of insulating fibers and weft composed of conductive fibers. As the insulating fiber, an organic fiber contained in the conductive fiber can be used. When conductive fibers are used as the wefts and insulating fibers are used as the warps, the carbon nanotubes can be prevented from falling off.

  As shown in FIG. 3, the heating element 14 of this embodiment is bonded to the back plate 15 with an adhesive (specifically, a fourth adhesive sheet 24), but a conductive material is formed on the back plate 15. May be formed. In this case, since the 4th adhesive sheet 24 is unnecessary, the solar cell module main body 10 can be reduced in thickness.

  The heating element 14 of the present embodiment is preferably a planar heating element in order to suppress heating unevenness, but may be a mesh heating element, a rod-like heating element, or the like.

The electrical insulating sheet 13 is disposed between the solar battery cell 12 and the heating element 14. The electrical insulating sheet 13 preferably has a volume resistivity of 10 ¹² Ω · cm or more (23 ° C., 50% RH). The electrical insulating sheet 13 is bonded to the heating element 14 by, for example, an adhesive (specifically, the third adhesive sheet 23). The electrical insulating sheet 13 may be formed of either resin or glass. The electrical insulating sheet 13 may be either a single layer or a multilayer. The electrical insulating sheet 13 may be either transparent or opaque.

  The heat resistance temperature of the electrical insulating sheet 13 is higher than the bonding temperature. The adhesive can flow by heating and compression in the bonding step S12. Since the adhesive (second adhesive sheet 22 and third adhesive sheet 23 in FIG. 2) between the solar battery cell 12 and the heating element 14 also flows due to heating above the melting point, conventionally, the solar battery cell 12 and the heating element 14 There was a possibility of contact. According to this embodiment, the presence of the electrical insulating sheet 13 can prevent contact between the heating element 14 and the solar battery cell 12.

  The heat resistant temperature of the electrical insulating sheet 13 refers to an upper limit temperature at which the electrical insulating sheet 13 can keep its shape (upper limit temperature at which damage or the like is not likely to occur during the manufacture of the solar cell module).

  When the electrical insulating sheet 13 is formed of resin, the heat resistant temperature is the melting point of the resin. Examples of the resin include polyethylene terephthalate (PET). The melting point of PET is about 260 ° C.

  When the electrical insulating sheet 13 is formed of glass, the heat resistant temperature is the softening point. Examples of the glass include soda lime glass, aluminosilicate glass, and alkali-free glass. For example, the softening point of soda lime glass is about 730 ° C.

  As shown in FIG. 3, the electrical insulating sheet 13 of the present embodiment is bonded to the heating element 14 by an adhesive (specifically, the third adhesive sheet 23). However, the heating element 14 is a planar heating element. In some cases, an electric insulating material may be formed on the planar heating element. In this case, since the 3rd adhesive sheet 23 is unnecessary, the solar cell module main body 10 can be reduced in thickness.

  FIG. 4 is a cross-sectional view illustrating a solar cell module according to an embodiment of the present invention. The solar cell module 30 includes, for example, the solar cell module main body 10, a frame 31, a beam 32, and a terminal box 33.

  The frame 31 supports the outer periphery of the solar cell module main body 10 to suppress deformation of the solar cell module main body 10 due to an external force such as wind pressure. The frame 31 has a groove 31a on the inner peripheral surface. The outer peripheral portion of the solar cell module body 10 is fixed by the fixing member 34 inside the groove 31a.

  A part of the heating element 14 is disposed inside the groove 31a. Since the heating element 14 is incorporated in the solar cell module body 10, unlike the conventional case where the heating element is arranged on the back side of the solar cell module body, the heating element 14 does not need to avoid the frame 31. The frame 31 can be heated and the snow on the frame 31 can melt.

  The beam 32 is connected to the frame 31. The beam 32 is attached to the back surface of the solar cell module main body 10 and suppresses deformation of the solar cell module main body 10 due to an external force such as wind pressure.

  In plan view (viewed in a direction perpendicular to the light receiving surface 10a and the back surface 10b), part of the heating element 14 and at least part of the beam 32 overlap. Since the heating element 14 is incorporated in the solar cell module body 10, unlike the conventional case where the heating element is arranged on the back side of the solar cell module body, the heating element does not have to avoid beams. The heating element 14 can be disposed at the position of the beam 32 in plan view, and the light receiving surface 10a can be heated uniformly.

  The terminal box 33 is attached to the back surface 10 b of the solar cell module body 10. The terminal box 33 accommodates a connection terminal that electrically connects the solar cell module body 10 and an external device (for example, another solar cell module body).

  In plan view, a part of the heating element 14 and at least a part of the terminal box 33 overlap. Since the heating element 14 is incorporated in the solar cell module body 10, unlike the conventional case where the heating element is arranged on the back side of the solar cell module body, the heating element does not have to avoid the terminal box. The heating element 14 can be disposed at the position of the terminal box 33 in plan view, and the light receiving surface 10a can be heated uniformly. For this reason, snow does not remain in the portion corresponding to the terminal box on the light receiving surface, and the power generation efficiency is improved.

  The solar cell module main body and the manufacturing method thereof, the solar cell module and the manufacturing method thereof, and the like have been described above. However, the present invention is not limited to the above embodiment and the like, and the present invention described in the claims. Various modifications and improvements are possible within the scope of the gist.

DESCRIPTION OF SYMBOLS 10 Solar cell module 10a Light-receiving surface 10b Back surface 11 Light-receiving surface plate 12 Solar cell 13 Electrical insulation sheet 14 Heat generating body 15 Back plate 16 Assembly 17 Adhesive layer 21 1st adhesive sheet 22 2nd adhesive sheet 23 3rd adhesive sheet 24 4th Adhesive sheet 30 Solar cell module 31 Frame 31a Groove 32 Beam 33 Terminal box

Claims (24)

The light-receiving face plate, solar cells, electrical insulating sheet, heating element, and back plate are arranged in this order from the light-receiving face side to the back face, heated to the bonding temperature, and bonded using an adhesive. Having a process,
The manufacturing method of the solar cell module main body whose heat-resistant temperature of the said electric insulation sheet is higher than the said adhesion temperature.   The method for manufacturing a solar cell module body according to claim 1, wherein the electrical insulating sheet is formed of a resin, and the heat-resistant temperature is a melting point of the resin.   The method for manufacturing a solar cell module body according to claim 1, wherein the electrical insulating sheet is made of glass, and the heat-resistant temperature is a softening point of the glass.   The said heat generating body is a manufacturing method of the solar cell module main body of any one of Claims 1-3 which is a planar heat generating body. The planar heating element has a heating part formed of a knitted fabric containing conductive fibers, and an electrode part for energizing the heating part,
The manufacturing method of the solar cell module main body of Claim 4 with which the said electroconductive fiber contains an organic fiber and the carbon nanotube which coat | covers the surface of the said organic fiber.   The method for manufacturing a solar cell module body according to claim 5, wherein the knitted fabric is a woven fabric composed of warps composed of insulating fibers and weft composed of conductive fibers.   The method for manufacturing a solar cell module body according to claim 4, wherein the planar heating element is formed by forming a conductive material on the back plate.   The method for manufacturing a solar cell module body according to claim 4, wherein the electrical insulating sheet is formed by forming an electrical insulating material on the planar heating element. A solar cell module manufacturing method comprising a solar cell module main body and a frame that supports the outer periphery of the solar cell module main body,
The manufacturing method of a solar cell module using the manufacturing method of any one of Claims 1-8. The frame has, on an inner peripheral surface, a groove in which an outer peripheral portion of the solar cell module body is disposed,
The method for manufacturing a solar cell module according to claim 9, wherein a part of the heating element is disposed inside the groove. A beam connected to the frame;
The beam is attached to the back surface of the solar cell module body,
The method for manufacturing a solar cell module according to claim 9 or 10, wherein a part of the heating element overlaps at least a part of the beam in a plan view. A terminal box for accommodating a connection terminal for connecting the solar cell module body and an external device;
The terminal box is attached to the back surface of the solar cell module body,
The method for manufacturing a solar cell module according to any one of claims 9 to 11, wherein a part of the heating element overlaps at least a part of the terminal box in plan view. The light-receiving face plate, solar cells, electrical insulation sheet, heating element, and back plate are arranged in this order from the light-receiving face side to the back side, heated to the bonding temperature, and bonded using an adhesive. And
The solar cell module main body whose heat-resistant temperature of the said electrical insulation sheet is higher than the said adhesion temperature.   The solar cell module body according to claim 13, wherein the electrical insulating sheet is formed of a resin, and the heat-resistant temperature is a melting point of the resin.   The solar cell module body according to claim 13, wherein the electrical insulating sheet is made of glass, and the heat-resistant temperature is a softening point of the glass.   The solar cell module body according to any one of claims 13 to 15, wherein the heating element is a planar heating element. The planar heating element has a heating part formed of a knitted fabric containing conductive fibers, and an electrode part for energizing the heating part,
The solar cell module main body according to claim 16, wherein the conductive fiber includes an organic fiber and a carbon nanotube covering a surface of the organic fiber.   The solar cell module body according to claim 17, wherein the knitted fabric is a woven fabric composed of warps composed of insulating fibers and wefts composed of the conductive fibers.   The solar cell module body according to claim 16, wherein the planar heating element is formed by depositing a conductive material on the back plate.   The solar cell module body according to any one of claims 16 to 19, wherein the electrical insulating sheet is formed by forming an electrical insulating material on the planar heating element. The solar cell module main body according to any one of claims 13 to 20,
The solar cell module which has a frame which supports the outer peripheral part of the said solar cell module main body. The frame has, on an inner peripheral surface, a groove in which an outer peripheral portion of the solar cell module body is disposed,
The solar cell module according to claim 21, wherein a part of the heating element is disposed inside the groove. A beam connected to the frame;
The beam is attached to the back surface of the solar cell module body,
The solar cell module according to claim 21 or 22, wherein a part of the heating element overlaps at least a part of the beam in plan view. A terminal box for accommodating a connection terminal for connecting the solar cell module body and an external device;
The terminal box is attached to the back surface of the solar cell module body,
The solar cell module according to any one of claims 21 to 23, wherein a part of the heating element overlaps at least a part of the terminal box in a plan view.

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